JP5419962B2 - Swirler and method of manufacturing - Google Patents

Description

  The present invention relates generally to swirlers, and more particularly to a single swirler for promoting fuel and air mixing in a fuel nozzle for use in a gas turbine engine.

  A turbine engine typically includes a plurality of fuel nozzles for supplying fuel to an engine combustor. The fuel is introduced in a very fine spray from the fuel nozzle at the front end of the burner. The compressed air flows around the fuel nozzle and is mixed with the fuel to produce a mixture, which is ignited by the burner. Due to the limited fuel pressure available and the wide range of required fuel flow, many fuel injectors include a pilot nozzle and a main nozzle, and only the pilot nozzle is used during start-up and high power Both nozzles are used during operation. The flow to the main nozzle decreases or stops during start-up and low power operation. Such injectors are more efficient and cleaner than single-nozzle fuel injectors because they can control fuel flow more accurately and direct fuel spray more accurately to meet specific combustor requirements. Can burn. The pilot nozzle and the main nozzle can be housed in the same nozzle assembly or can be supported in separate nozzle assemblies. These dual-nozzle fuel injectors can also be configured to allow further control of the fuel for the dual combustor, resulting in higher fuel efficiency and reduced harmful emissions. The temperature of the ignited mixture can reach higher than 3500 ° F. (1920 ° C.). It is therefore important that the fuel supply conduits, flow paths and distribution system are substantially leak free and protected from flame and heat.

  Various government regulatory bodies have identified acceptable emission limits for unburned hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx), which have been identified as the main causes of undesirable atmospheric conditions. I have set it. Accordingly, various combustor designs have been developed to meet those standards. For example, one way to address the challenge of minimizing emissions of undesirable gas turbine engine combustion products is to provide multi-stage combustion. In this configuration, a combustor is provided in which the first stage burner is utilized at low speed and low power conditions to more closely control the properties of the combustion products. The first and second stage burners are combined to seek higher power conditions while trying to keep the combustion products within emission limits. It is understood that balancing the operation of the first and second stage burners is difficult to achieve so as to enable efficient thermal operation of the engine while at the same time minimizing the production of undesirable combustion products. Let's be done. In that regard, operating at lower combustion temperatures to reduce NOx emissions can result in incomplete or partially incomplete combustion, which results in lower power and lower thermal efficiency. In addition, it can lead to the production of excess HC and CO. On the other hand, high combustion temperatures improve thermal efficiency and reduce the amount of HC and CO, but often result in higher NOx emissions. In the art, one of the ways in which the generation of undesirable combustion product components in a gas turbine engine combustor is minimized throughout the engine operating situation is to use multistage combustion using primary and secondary fuel injection ports. Is to use the system.

  Another method that has been proposed to minimize the production of these undesirable combustion product components is to provide a more effective method of mixing the injected fuel and combustion air. In that regard, numerous swirler and mixer designs have been proposed over the years to improve fuel and air mixing. In this way, constant combustion occurs throughout the mixture, reducing the level of HC and CO due to incomplete combustion. However, there is still a need to minimize the production of undesirable combustion products over a wide range of engine operating conditions. Better mixing of fuel and air at the fuel nozzle using a swirler design that facilitates such mixing would be useful in reducing undesirable combustion emissions.

  Exposure to high temperatures during long periods of turbine engine operation may induce thermal stresses in the conduit and fuel nozzle, which may damage the conduit and fuel nozzle, and the conduit and fuel. There is a possibility of adversely affecting the operation of the nozzle. For example, thermal stress can cause a reduction in fuel flow in the conduit and can lead to an uneven distribution of excess fuel in the turbine engine. Exposure of fuel flowing through fuel nozzle conduits and orifices to high temperatures can lead to coking of the fuel, which can lead to blockage and uneven flow. In order to achieve low emissions, modern fuel nozzles require a large number of complex internal air and fuel circuits to create multiple separate flame zones. The fuel circuit may require a heat shield from internal air to prevent coking, and certain tip regions may need to be cooled and shielded from combustion gases. Further, operating with fuel nozzles that have been damaged continuously for a long time may reduce turbine efficiency, damage turbine components, and / or reduce engine exhaust gas temperature margins.

  If the life cycle of the fuel nozzle installed in the turbine engine is improved, the life of the turbine engine can be extended. Known fuel nozzles include a delivery system and a support system. A delivery system that includes a conduit for transporting fluid delivers fuel to the turbine engine and is supported and shielded within the turbine engine by a support system. More particularly, the known support system surrounds the delivery system and is therefore exposed to higher temperatures and has a higher operating temperature than the delivery system cooled by the fluid flowing through the fuel nozzle. By setting the outer and inner contours and thicknesses, thermal stresses in the conduit and fuel nozzle can be reduced.

  The air / fuel mixer has a swirler assembly that swirls the air passing through the swirler assembly and facilitates the mixing of air and fuel prior to combustion. The swirler assembly used in the combustor can be a complex structure with axial, radial, or conical swirlers or combinations thereof. In the past, conventional manufacturing methods have been used to produce mixers with swirler components, which are assembled or joined using known methods to form a swirler assembly. . For example, in some mixers with complex vanes, the individual vanes are first machined and then brazed to the assembly. In the past, investment casting methods have been used in making several combustion swirlers. Other swirlers have been machined from raw materials. Electrical Discharge Machining (EDM) has been used as a means of machining conventional swirler vanes.

  For example, conventional gas turbine engine components such as fuel nozzles and their associated swirlers, conduits, distribution systems, etc. are typically expensive to manufacture and / or repair. This is because conventional fuel nozzle designs with complex swirlers, conduits and distribution circuits for transporting, distributing, and mixing fuel have complex assemblies and more than 30 component connections. Is included. More particularly, the use of a brazed joint may increase the time required to produce the component, and the need for a proper area to allow placement of the braze alloy is unnecessary. The need to minimize brazing alloy flow, the need for acceptable inspection techniques to verify brazing quality, and some brazes that can be used to prevent remelting of the previous brazed joint The fabrication process can be complicated for any of several reasons, including the need to have a brazing alloy. In addition, many brazed joints may result in several braze runs that can weaken the matrix of the component. The presence of a large number of brazed joints is undesirable because it may increase the weight and manufacturing costs of the component parts.

  Accordingly, it would be desirable to have a swirler with a complex shape for mixing liquid fuel and air within a fuel nozzle having a unitary structure in order to reduce the undesired effects from the thermal exposure. It would be desirable to have a swirler with a complex shape with a unitary structure to reduce costs, facilitate assembly, and provide protection from a hot environment. For example, it would be desirable to have a manufacturing method for providing a unitary structure to a unitary swirler having a complex three-dimensional shape for transporting air, such as a fuel nozzle swirler system.

  The need described above can be met by an exemplary embodiment that includes a body having a swirler axis and a plurality of vanes arranged circumferentially around the swirler axis, providing a unitary swirler having a unitary structure. . In another embodiment, the unitary swirler has a rim that is coaxial with the swirler axis and a wall that extends between a portion of the rim and a portion of the hub. In another embodiment, the unitary swirler has an adapter having a passage configured to direct air flow toward at least some of the plurality of vanes. In another embodiment, the unitary swirler has at least one vane having a different shape than another vane. In another embodiment, the unitary swirler has a body with an insulating gap located at least partially within the body.

  In another aspect of the invention, three-dimensional information is determined for a single swirler having a plurality of vanes circumferentially arranged on the body about the swirler axis and a wall extending between the rim and a portion of the body. Converting the three-dimensional information into a plurality of slices, each slice defining a cross-sectional layer of the single swirler, and forming each layer of the single swirler one after another by dissolving the metal powder using laser energy A method for making a single swirler is disclosed. An exemplary embodiment is disclosed that illustrates a unitary swirler that is manufactured using a rapid manufacturing process. In one aspect of the invention, the rapid manufacturing process is a laser sintering process.

  The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. However, the present invention is best understood by referring to the following description in conjunction with the accompanying drawings.

1 is a schematic view of a high bypass turbofan gas turbine engine including an exemplary fuel nozzle having a swirler according to an exemplary embodiment of the present invention. FIG. 1 is an isometric view of an exemplary fuel nozzle having a swirler according to an exemplary embodiment of the present invention. FIG. FIG. 3 is an axial cross-sectional view of an exemplary nozzle tip assembly of the exemplary fuel nozzle shown in FIG. 2 is an isometric view of a swirler according to an exemplary embodiment of the present invention. FIG. FIG. 5 is a plan view of the exemplary swirler shown in FIG. 4 with a portion cut away. FIG. 5 is another isometric view of the exemplary swirler shown in FIG. 4. FIG. 6 is an isometric view of a swirler according to an alternative exemplary embodiment of the present invention with a portion of the swirler cut away. FIG. 8 is a plan view of the alternative exemplary swirler shown in FIG. 7 with a portion cut away. FIG. 6 is an isometric view of a swirler according to another alternative exemplary embodiment of the present invention with a portion of the swirler cut away. FIG. 10 is a plan view of the alternative exemplary swirler shown in FIG. 9 with a portion cut away. FIG. 6 is an axial cross-sectional view of another alternative exemplary embodiment of the present invention of a swirler showing coupling with adjacent components. FIG. 6 is an axial cross-sectional view of another alternative exemplary embodiment of the present invention of a swirler showing coupling with adjacent components. 2 is a flow diagram illustrating an exemplary embodiment of a method for making a unitary swirler.

  Referring now in detail to the drawings in which like numerals indicate like elements throughout the figures, FIG. 1 illustrates a swirler (shown in the figures and illustrated in FIG. 1 illustrates in schematic form an exemplary gas turbine engine 10 (high bypass type) incorporating an exemplary fuel nozzle 100 having an exemplary embodiment of items 200, 300, 400, etc., as described herein. The exemplary gas turbine engine 10 has an axial centerline axis 12 therethrough for reference purposes. Engine 10 desirably includes a core gas turbine engine, generally identified by numeral 14, and a fan section 16 disposed upstream therefrom. The core engine 14 typically includes a generally tubular outer casing 18 that defines an annular inlet 20. The outer casing 18 further surrounds and supports the booster 22 to increase the pressure of air entering the core engine 14 to a first pressure level. The high-pressure, multistage axial compressor 24 receives compressed air from the booster 22 and further increases the pressure of the air. The compressed air flows to the combustor 26 where fuel is injected into the compressed air stream and ignites, increasing the temperature and energy level of the compressed air. The high energy combustion products flow from the combustor 26 to the first (high pressure) turbine 28 to drive the high pressure compressor 24 via the first (high pressure) drive shaft 30, and then the first drive shaft 30. To the second (low pressure) turbine 32 to drive the booster 22 and the fan section 16 via a second (low pressure) drive shaft 34 that is coaxial with the. After driving each of the turbines 28 and 32, the combustion products leave the core engine 14 via the exhaust nozzle 36 and provide at least a portion of the jet propulsion thrust of the engine 10.

  The fan section 16 includes a rotatable axial fan rotor 38 surrounded by an annular fan casing 40. It will be appreciated that the fan casing 40 is supported from the core engine 14 by a plurality of circumferentially spaced outlet guide vanes 42 that extend substantially radially. Thus, the fan casing 40 surrounds the fan rotor 38 and the fan rotor blade 44. The downstream section 46 of the fan casing 40 extends over the outer portion of the core engine 14 and defines a secondary or bypass airflow conduit 48 that provides additional jet propulsion thrust.

  From a flow point of view, it will be appreciated that the initial air flow, indicated by arrow 50, enters gas turbine engine 10 through inlet 52 to fan casing 40. The air flow 50 passes through the fan blade 44 and is divided into a first compressed air flow (indicated by arrow 54) that travels through the conduit 48 and a second compressed air flow (indicated by arrow 56) that enters the booster 22. Divided into

  The pressure of the second compressed air stream 56 increases and enters the high pressure compressor 24 as indicated by arrow 58. After being mixed with fuel and combusted in the combustor 26, the combustion product 60 exits the combustor 26 and flows through the first turbine 28. The combustion product 60 then flows through the second turbine 32 and exits the exhaust nozzle 36 to provide at least a portion of the thrust of the gas turbine engine 10.

  Combustor 26 includes a longitudinal combustion chamber 12 and an annular combustion chamber 62 that is coaxial with inlet 64 and outlet 66. As described above, the combustor 26 receives an annular flow of compressed air from the high pressure compressor discharge outlet 69. A portion of this compressor exhaust air (“CDP” air), identified by numeral 190 in the drawings herein, flows into a mixer (not shown). Fuel is injected from the fuel nozzle tip assembly and mixes with air, producing an air-fuel mixture that is provided to the combustion chamber 62 for combustion. Ignition of the air-fuel mixture is achieved by a suitable igniter, and the resulting combustion gas 60 flows axially into and into the annular, first stage turbine nozzle 72. The nozzle 72 includes a plurality of radially extending circumferentially spaced nozzle vanes 74 that rotate the gas so that the gas flows at an angle and acts on the first stage turbine blades of the first turbine 28. It is defined by an annular channel. As shown in FIG. 1, the first turbine 28 preferably rotates the high pressure compressor 24 via a first drive shaft 30. The low pressure turbine 32 preferably drives the booster 22 and the fan rotor 38 via the second drive shaft 34.

  The combustion chamber 62 is accommodated in the engine outer casing 18. The fuel is supplied to the combustion chamber by the fuel nozzle 100 as in the example shown in FIGS. Liquid fuel is transported to the fuel nozzle tip assembly 68, for example, via a conduit in the stem 103 as shown in FIG. A conduit having a unitary structure may be used to transport liquid fuel to the fuel nozzle tip assembly 68 of the fuel nozzle 100. A fuel supply conduit may be located in the stem 103 and coupled to the fuel distributor tip 180. Pilot fuel and main fuel are injected into the combustor 26 by a fuel nozzle tip assembly 68, for example, as shown in FIGS. During operation of the turbine engine, initially, pilot fuel is supplied via pilot fuel passages, such as shown as items 102, 104 in FIG. 3, during predetermined engine operating conditions such as starting and idling. Pilot fuel is discharged from the fuel distributor tip 180 via the pilot fuel outlet 162. When additional power is required, main fuel is supplied via the main fuel passage 105 (see FIG. 3) and the main fuel is injected using the main fuel outlet 165.

  4-6 illustrate an exemplary embodiment of the present invention of a unitary swirler 200. FIG. FIGS. 2 and 3 illustrate an exemplary embodiment of a fuel nozzle tip 68 having a fuel nozzle 100 and an exemplary unitary swirler 200. FIGS. 7-10 illustrate alternative exemplary embodiments of unitary swirlers 300,400. The term “unitary” is used in this application to mean that related components such as the swirlers 200, 300, 400 described herein are manufactured as a single piece during manufacture. Thus, a single component has an integral structure for that component. FIG. 4 shows an isometric view of a unitary swirler 200 according to an exemplary embodiment of the present invention. The exemplary swirler 200 shown in FIG. 4 includes circumferentially arranged vanes 208 that provide a swirling motion to the air passing through the vanes. The exemplary swirler 200 shown in FIG. 4 may have a unitary structure that is subsequently manufactured using the methods described herein.

  Referring to FIGS. 2 and 3, the fuel distributor tip 180 is configured such that the main fuel passage 105 and the pilot fuel passages 102, 104 of the unitary distributor ring 171 are in flow communication with corresponding fuel supply conduits contained within the stem 103. Extending from the stem 103 to be coupled together. The main fuel passage 105 is coupled in flow communication with a main fuel circuit defined within the unitary distributor ring 171. Primary pilot passage 102 and secondary pilot passage 104 are coupled in flow communication with corresponding pilot injectors disposed radially inward within the fuel nozzle (see FIG. 3). Distributor ring 171 is described herein above as a unitary conduit (ie, having a unitary structure), but uses a distributor ring 107 having other suitable manufacturing structures using methods known in the art. It will be apparent to those skilled in the art that this is possible. The single distributor ring 171 is connected to the stem 103 using conventional connection means such as brazing. Alternatively, the single distributor ring 171 and the stem 103 may be manufactured by a rapid manufacturing method such as, for example, direct laser metal sintering as described herein.

  FIG. 3 shows an axial cross section of an exemplary fuel nozzle tip 68 having an exemplary embodiment of the present invention of a unitary swirler 200. The exemplary fuel nozzle tip 68 shown in FIG. 3 has two pilot channels, referred to herein as primary pilot channel 102 and secondary pilot channel 104. Referring to FIG. 3, fuel from the primary pilot flow path 102 exits the fuel nozzle via the primary pilot fuel injector 163, and fuel from the secondary pilot flow path 104 is secondary pilot fuel injection. The fuel nozzle exits through the vessel 167. The primary pilot flow path 102 of the distributor ring 171 is in flow communication with the corresponding pilot primary passage of the supply conduit contained within the stem 103 (see FIG. 2). Similarly, the secondary pilot flow path 104 of the distributor ring 171 is in flow communication with a corresponding pilot secondary passage of a supply conduit contained within the stem 103.

  As mentioned above, fuel nozzles such as fuel nozzles used in gas turbine engines are exposed to high temperatures. Such exposure to high temperatures can cause fuel coking and blockage in fuel passages such as, for example, outlet passage 164, in some cases. One way to mitigate fuel coking and / or blockage of the distributor ring 171 is to use heat shields to protect the aisles (items 102, 104, 105, etc. shown in FIG. 3) from a hot environment. It is. In the exemplary embodiment shown in FIG. 3, the fuel conduits 102, 104, 105 are protected by gaps 116 and heat shields that at least partially surround these conduits. The gap 116 provides protection to the fuel passage by providing insulation from a bad heat environment. In the exemplary embodiment shown, the insulating gap 116 has a width between about 0.015 inches and about 0.025 inches. The heat shield can be made of any suitable material with the ability to withstand high temperatures, such as, for example, cobalt and nickel based alloys commonly used in gas turbine engines. In the exemplary embodiment shown in FIG. 3, the distributor ring 171 is formed such that the distributor ring 171, the flow paths 102, 104, 105, the fuel outlet 165, the heat shield and the gap 116 have a unitary structure. It has a single structure.

  FIG. 4 shows an isometric view of a swirler 200 according to an exemplary embodiment of the present invention. The exemplary swirler 200 includes a body 201 having a hub 205 that extends circumferentially about the swirler axis 11. A row of vanes 208 extending from the hub 205 are arranged circumferentially on the hub 205 around the swirler shaft 11. Each vane 208 has a blade root 210 located radially near the hub 205 and a blade tip 220 located radially outward from the hub 205. Each vane 208 has a leading edge leading edge 212 and a trailing edge trailing edge 214 extending between the blade root 210 and the blade tip 220. The vane 208 has a suitable shape, such as an airfoil shape, between the leading edge 212 and the trailing edge 214, for example. Adjacent vanes form a flow path for passing air, such as CDP air, shown as item 190 in FIG. The vane 208 can be tilted radially and axially relative to the swirler shaft 11 to provide a rotational element of motion for the incoming air 190 entering the swirler 200. These inclined swirler vanes 208 swirl the air 190 in a generally spiral manner within the fuel nozzle tip assembly 68. In one aspect of the invention, the vane 208 has a fillet 226 that extends between the blade root 210 and the hub 205. In addition to helping reduce stress concentrations at the blade root 210, the fillet 226 also helps smooth the air flow in the swirler hub region. The fillet 226 has a smooth contour shape 227 designed to aid in the smooth flow of swirler air. The contour shape and orientation of a particular vane 208 is designed using known methods of fluid flow analysis. In the exemplary embodiment shown in FIGS. 3-11 herein, the vane 208 has a cantilever type support, and the vane is at the blade root 210 with the vane tip 220 essentially free. Structurally supported on the hub 205. In some alternative swirler designs, additional structural support is provided in the tip region 220 for at least some of the vanes 208, for example as shown in FIG. 12 illustrating an alternative embodiment of the present invention. It is also possible to provide. In another aspect of the invention, a recess 222 is provided at the wing tip 220 of the vane 228, for example as shown in FIGS. The recess 222 engages adjacent components of the fuel nozzle 100 to orient the adjacent components of the fuel nozzle 100 in the axial direction, as shown, for example, in FIGS. In the exemplary embodiment shown in FIGS. 4 and 5, the recess 222 includes a step having a stepped change in radius at the vane tip 220. It will be apparent to those skilled in the art that the recess 222 can have other locations or other geometric shapes on the vane 208.

  The exemplary swirler 200 shown in FIGS. 3-5 includes an adapter 250 located axially rearward from a circumferential row of vanes 208. The adapter 250 includes an arcuate wall 256 (see FIG. 6) that forms a flow path 254 for delivering an air flow 190, such as, for example, a CDP air flow exiting the compressor discharge of the turbofan engine 10 (see FIG. 1). including. Incoming air 190 enters passage 254 of adapter 250 and flows axially forward toward the row of vanes 208 of swirler 200. In one aspect of the invention, a portion 203 of the swirler body 201 extends axially rearward from the hub 205 and forms a portion of the adapter 250. In the exemplary embodiment shown in FIG. 6, a portion 203 of the body 201 that extends rearward in the axial direction forms part of the arcuate wall 256 of the adapter 250. The adapter 250 also serves as a means for mounting the swirler 200 on an assembly, such as the fuel nozzle assembly 68, as shown in FIG. In the exemplary embodiment shown in FIG. 6, the adapter 250 receives a brazing material (not shown) used to connect the adapter 250 to another structure, such as the fuel nozzle stem 103 shown in FIG. Including an arcuate groove 252 for the purpose. As can be clearly seen in FIG. 6, the groove 252 of the arcuate wall 256 has a complex three-dimensional shape that is difficult to form using conventional machining methods. In one aspect of the present invention, the groove 252 of the arched wall 256 having a complex three-dimensional shape as shown in FIGS. 4-10 can be used to produce a unitary structure using the manufacturing methods described hereinbelow. Are integrally formed.

  The exemplary swirler 200 shown in FIGS. 3-5 includes an annular rim 240 that is coaxial with the swirler shaft 11 and located radially outward from the hub 205. As seen in FIGS. 3, 11, and 12, the rim 240 engages adjacent components of the fuel nozzle 100 and forms part of a flow path for flowing air 190 through the swirler 200. Airflow 190 enters the rear portion of swirler 200 axially forward and is directed toward vane 208 by hub 205 and rim 240. In the exemplary embodiment shown in FIGS. 4-6, an air flow 190, such as from a compressor discharge, enters the passage 254 of the adapter 250. As best seen in FIGS. 5 and 6, the axial forward end of arcuate wall 256 of adapter 250 integrally connects to rim 240 and body 201. In a preferred embodiment, adapter 250, rim 240, body 201, hub 205 and vane 208 have a unitary structure using the manufacturing methods described herein. Alternatively, the adapter 250 may be manufactured separately and connected to the rim 240 and the body 201 using conventional connection means.

  Referring to FIG. 4, the wall 260 extends between a portion of the rim 240 and a portion of the hub 205 of the body 201. Wall 260 provides at least part of the structural support between rim 240 and swirler hub 205. Wall 260 also ensures that air 190 entering the forward portion of the swirler from passage 254 of adapter 250 does not flow axially in the reverse direction and allows flow 190 to continue axially forward toward vane 208. . In the exemplary embodiment shown in FIG. 5, the front surface 262 of the wall 260 is substantially planar with respect to a plane perpendicular to the swirler axis 11. In order to facilitate the smooth flow of air, the ends of the walls 260 (see FIGS. 4 and 5) are shaped smoothly to avoid sudden flow separation at sharp corners.

  The compressor exhaust air 190 entering the combustor (see FIGS. 3 and 4) and the fuel nozzle region are very hot, with temperatures exceeding 800 ° F. (about 427 ° C.). It is common in the application of fuel nozzles. Such high temperatures may cause coking or other heat-induced failures in some of the internal components of the fuel nozzle 100, such as, for example, the fuel flow paths 102, 104 and the swirler 200. The high temperature of the air 190 may also weaken the internal brazed joint, such as between the fuel injector 163 and the distributor ring body (see FIG. 3). In one aspect of the invention, the insulating gap 216 reduces the transfer of heat from the air flowing to the swirler 100 and other internal components such as the primary fuel injector 163 or the secondary fuel injector 167. , Provided in the body 201 of the swirler 200. Insulating gaps, such as item 216, help reduce the temperature at the brazed joint of the fuel nozzle during engine operation. The insulating gap 216 may be annular as shown in FIGS. Other suitable shapes based on known heat transfer analysis may also be used. In the exemplary embodiment shown in FIG. 3, the insulating gap is an annulus that extends at least partially within the swirler body 201 and is about 0.015 inches and 0.025 inches. 064 cm) in the radial width of the gap. In one aspect of the invention, the insulating gap 216 has a unitary structure that is formed integrally with the swirler body 201 using the manufacturing methods described hereinbelow. An integrally formed brazing groove, such as the grooves described herein, has a complex profile and allows a pre-formed brazing ring (not shown) to be attached and facilitated Facilitates assembly.

  With reference to FIGS. 4 and 6, it will be apparent to those skilled in the art that the air flow 190 entering the adapter passage 254 is not circumferentially uniform as it enters the vane 208. This non-uniformity is further enhanced by the presence of walls 260. In conventional swirlers, this non-uniformity in the flow can cause non-uniform fuel and air mixing and can lead to non-uniform combustion temperatures. In one aspect of the present invention of swirler 200, the adverse effects of uneven circumferential inflow can be minimized by having swirler vanes 208 with shapes different from the shapes of circumferentially adjacent vanes. it can. The shape of the special swirler vane 208 can be selected for each circumferential position of the hub 205 based on known fluid flow analysis techniques. Swirlers having different shapes for vanes 208 located at different circumferential positions can have a unitary structure that is manufactured using the manufacturing methods described herein.

  An alternative exemplary embodiment of swirler 300 is shown in FIGS. An alternative exemplary embodiment of swirler 300 includes swirler vane 308, body 301, hub 305, adapter 350 and rim 340, similar to swirler 200 previously described herein. FIG. 7 is an isometric view of an alternative exemplary embodiment of swirler 300 with a portion of swirler rim 340 and wall 360 cut away. FIG. 8 is a plan view of the alternative exemplary swirler 300 shown in FIG. As noted above, the presence of walls such as walls 260 (see FIG. 5) may cause non-uniformity in the flow of air into the vanes 208, particularly those vanes 208 that are axially located in front of the walls 260. There is. One way to mitigate the non-uniformity of the flow near the wall is to reduce the separation of the flow 190 near the wall 200. This is achieved in an alternative exemplary embodiment of the swirler 300 by having a contoured wall 360 on the front surface 362, as shown in FIG. The aerodynamic profile for the wall 360 can be selected to reduce flow separation near the wall 360 based on known fluid flow analysis techniques. The improved flow direction near the wall 360, indicated by the flow arrows 191 (see FIG. 8), is more uniform air on the vanes 308, especially those vanes 308 that are axially located in front of the wall 360. Provide a flow of The adverse effects of uneven flow in the circumferential direction may have a smooth end on the wall 360 and / or a shape that is different from the shape of the circumferentially adjacent vane 308, as discussed above. Can be further minimized by having a swirler vane 309 with Alternative exemplary embodiments of swirler 300 having complex shapes on walls 360 and vanes 308, 309 can be manufactured using the manufacturing methods described herein.

  Another alternative exemplary embodiment of swirler 400 is shown in FIGS. An alternative exemplary embodiment of swirler 400 includes swirler vane 408, body 401, hub 405, adapter 450 and rim 440, similar to swirlers 200, 300 previously described herein. FIG. 9 is an isometric view of an alternative exemplary embodiment of swirler 400 with a portion of swirler rim 440 and wall 460 cut away. FIG. 10 is a plan view of the alternative exemplary swirler 400 shown in FIG. As described above, the presence of walls such as walls 260 (see FIG. 5) may cause non-uniformity in the flow of air into the vanes 208, particularly those vanes 208 that are axially located in front of the walls 260. There is. The non-uniformity of the flow near the wall can be reduced by reducing the separation of the flow 190 near the wall 200. This can be achieved in an alternative exemplary embodiment of the swirler 400 by having a wing 409 extending axially forward from the front surface 462 of the wall 460, as shown in FIGS. The aerodynamic profile of wall 460 and vane 409 may be designed to reduce flow separation near wall 360 based on known fluid flow analysis techniques. The improved flow direction near the wall 460, indicated by the flow arrows 191 (see FIG. 10), is more constant air on the vanes 408, 409, especially those vanes located axially in front of the wall 460. Provide flow. The negative effects of inflowing circumferentially uneven flows are different from having a smooth edge on the wall 460 and / or the shape of the circumferentially adjacent vane 408, as discussed above. By having more swirler wings 409 with shape, it can be further minimized. Alternative exemplary embodiments of the swirler 400 having complex shapes on the walls 460 and vanes 408, 409 can be manufactured by using the manufacturing methods described herein.

  FIGS. 11 and 12 illustrate alternative exemplary embodiments of the location of the wall 260. In the exemplary embodiment shown in FIG. 3, the wall 260 is located at the rearward end in the axial direction of the hub 205 of the body 201. In some applications, it may be advantageous to position the wall 260 axially forward, for example, to reduce mechanical vibrations. FIG. 11 illustrates an exemplary embodiment in which the wall 260 is located axially forward from the rear end of the hub 205 in a position that is axially rearward from the leading edge 212 of the vane 208. Alternatively, FIG. 12 shows another exemplary embodiment in which the wall 260 extends from the wing tip 220 of the vane 208. In some designs, the wall 260 may extend from the wing tips 220 of the plurality of vanes 208.

  The exemplary embodiment of the unitary swirler 200 shown in FIGS. 3-6 and the exemplary embodiments of the unitary swirlers 300, 400 shown in FIGS. 7-12 include direct metal laser sintering (DMLS), laser net shape fabrication ( LNSM), other processes known in electron beam sintering and manufacturing can be used to manufacture using rapid manufacturing processes. DMLS is a desirable method of manufacturing the single swirler 200, 300, 400 described herein.

  FIG. 13 is a flow diagram illustrating an exemplary embodiment of a method 500 for making a unitary swirler, such as items 200, 300 and 400 described herein and shown in FIGS. Although the fabrication method 500 is described below using a single swirler 200 as an example, the same methods, steps, procedures, etc. apply to the alternative exemplary embodiment of the swirler shown in FIGS. Method 500 includes fabricating a single swirler 200 (shown in FIGS. 3-6) using direct metal laser sintering (DMLS). DMLS is a known manufacturing process that uses three-dimensional information, eg, a three-dimensional computer model of a component, to produce a metal component. The three-dimensional information is converted into a plurality of slices, each slice defining a cross-section of a slice of a predetermined height. The component is then “built up” by slice or layer by layer until completion. Each layer of the component is formed by melting a metal powder using a laser.

  Accordingly, the method 500 includes a step 505 of determining the three-dimensional information of the single swirler 200 and a step 510 of converting the three-dimensional information into a plurality of slices, each slice defining a cross-sectional layer of the single swirler 200. Next, the unitary swirler 200 is fabricated using DMLS, or more specifically, each layer is formed one after another in step 515 by melting the metal powder using laser energy. Each layer has a dimension between about 0.0005 inches (about 0.0013 cm) and about 0.001 inches (about 0.0025 cm). The unitary swirler 200 may be fabricated using any suitable laser sintering machine. Examples of suitable laser sintering machines include, but are not limited to, EOS of North America, Inc., Novi, Michigan. Available from EOSINT. RTM. M270 DMLS machine, PHENIX PM250 machine, and / or EOSINT. RTM. An M 250 Xtended DMLS machine is included. The metal powder used to make the unitary swirler 200 is desirably a powder comprising cobalt chromium, but may be any other suitable metal powder such as, but not limited to, HS188 and INCO625. The metal powder can have a particle size between about 10 microns and 74 microns, but desirably between about 15 microns and about 30 microns.

  Although the method of manufacturing the unitary swirler 200 has been described herein as using DMLS as the preferred method, any other suitable rapid manufacturing method using layer-by-layer construction or additional fabrication can also be used. Those skilled in the art will appreciate. These alternative rapid manufacturing methods include, but are not limited to, selective laser sintering (SLS), 3D printing such as by inkjet and laser jet, stereolithography (SLS), direct selective laser sintering (DSLS), Electron beam sintering (EBS), electron beam melting (EBM), laser technology net shape method (LENS), laser net shape manufacturing (LNSM) and direct metal deposition (DMD) are included.

  A single swirler 200 for a fuel nozzle 100 of a turbine engine (see FIGS. 1-3) includes fewer components and couplings than known swirlers and fuel nozzles. Specifically, the unitary swirler 200 described above requires fewer components in order to use the unitary unitary swirler 200 that includes a plurality of vanes 208, body 201, rim 40, and wall 260. As a result, the single fuel swirler 200 described provides a lighter, less expensive alternative to known fuel swirlers. Furthermore, the described unitary structure for the unitary swirler 200 has fewer opportunities for leakage or failure compared to known swirlers and can be repaired more easily.

  As used herein, a step recited in the singular or lacking a number should be understood not to exclude a plurality of said elements or steps unless specifically stated to exclude a plurality. It is. When introducing the elements / components / steps, etc. of the single venturi 500, 600 described and / or illustrated herein, articles such as the absence of a numeral or “above” may refer to one or more elements / components. It is intended to mean that there is / etc. The terms “comprising”, “including” and “having” are inclusive and mean that there may be additional elements / components / etc. In addition to the listed elements / components / etc. Intended to be. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

  Although the methods described herein and articles such as unitary swirlers 200, 300, 400 are described in the context of swirling air to mix liquid fuel with turbine engine air, It should be understood that the single swirlers 200, 300, 400 and their method of manufacture described in are not limited to fuel nozzles or turbine engines. The single swirlers 200, 300, 400 depicted in the drawings included herein are not limited to the specific embodiments described herein, but rather are other components described herein. Independently and independently available.

  This written description uses the examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples may have structural elements that do not differ from the wording terms of the claims, or the illustrations may differ only slightly from the wording terms of the claims. The accompanying equivalent structural elements are intended to be within the scope of the claims.

DESCRIPTION OF SYMBOLS 10 Gas turbine engine 11 Swirler shaft 12 Axial centerline shaft 14 Core gas turbine engine 16 Fan section 18 Outer casing 20 Inlet 22 Booster 24 High pressure multistage axial compressor 26 Combustor 28 First (high pressure) turbine 30 First (high pressure) ) Drive shaft 32 Second (low pressure) turbine 34 Second (low pressure) drive shaft 36 Exhaust nozzle 38 Axial fan rotor 40 Fan casing 42 Guide vane 44 Fan rotor blade 46 Downstream section 48 Air flow conduit 50 Air flow 52 Inlet 54 Air Flow 56 Air flow 58 Air flow 60 Combustion products / combustion gas 62 Combustion chamber 64 Inlet 66 Outlet 68 Fuel nozzle tip assembly 69 High pressure compressor discharge outlet 72 Turbine nozzle 74 Nozzle vane 100 Fuel nozzle 102 Pilot fuel passage 103 Stem 104 Pilot fuel passage 105 Main fuel passage 116 Insulation gap 162 Pilot fuel outlet 163 Pilot fuel injector 164 Outlet passage 165 Main fuel outlet 167 Pilot fuel injector 171 Distributor ring 180 Fuel distributor tip 190 Compressor discharge Air / “CDP” air 191 Air flow 200 Swirler 201 Swirler body 203 Part of swirler body 205 Hub 208 Vane 209 Vane 210 Blade root 212 Front edge 214 Rear edge 216 Insulation gap 220 Blade end 222 Recess 226 Fillet 227 Smooth contour 240 Rim 250 Adapter 252 Groove 254 Adapter passage 256 Arched wall 260 Wall 262 Front surface 300 Swirler 301 Swirler body 305 hub 308 vane 309 vane 320 wing tip 322 recess 340 rim 350 adapter 360 wall 362 front surface 364 contour 400 swirler 401 swirler body 405 hub 408 vane 409 vane 440 swirler rim 450 adapter 460 wall 462 front surface

Claims (30)

A body (201) including a swirler hub (205) having a swirler shaft (11);
A plurality of vanes (208) extending from the hub (205) and arranged circumferentially around the swirler axis (11);
A rim (240) positioned coaxially with the swirler shaft (11);
A wall (260) extending between a portion of the rim (240) and a portion of the hub (205) ;
An adapter (250) having a passage (254) configured to direct the flow of air toward at least some of the plurality of vanes (208) ;
The passage (254) is formed by an arched wall (256) extending from a portion of the body (201);
A swirler (200) having a unitary structure. It said passage (254) is formed by arcuate wall (256) extending from a portion of said rim (240) of claim 1, wherein a swirler (200). It has a groove (252) capable of receiving said adapter (250) brazed material, according to claim 1, wherein a swirler (200). The swirler (200) of claim 1, wherein the body (201) has an insulating gap (216) located at least partially within the body (201). The swirler (200) of any preceding claim, wherein each vane (208) has substantially the same shape. The swirler (200) of any preceding claim, wherein at least one vane (209) has a different shape than another vane (208). The swirler (200) of any preceding claim, wherein the wall (260) has an axial forward surface (262) that is substantially planar. The swirler (300) of any preceding claim, wherein the wall (360) has an axial forward surface (362) having a contour (364) that facilitates a smooth flow of air. The swirler (400) of any preceding claim, wherein at least one vane (409) extends from an axial forward surface (462) of the wall (460). The swirler (300) of any preceding claim, wherein the at least one vane (308) has a free wing tip (320). The swirler (300) of claim 10 , wherein at least one vane (308) has a recess (322) that extends into a portion of the wing tip (320). The swirler (200) of claim 1, wherein the wall (260) is located at an axial rear end of the hub (205). The swirler (200) of claim 1, wherein the wall (260) is located axially forward from a rear end of the hub (205). The swirler (200) of any preceding claim, wherein the wall (260) extends from the wing tip (220) of a vane (208). A method (500) for making a single swirler (200),
A plurality of vanes (208) arranged circumferentially on the body (201) around the swirler axis (11) and a wall (260) extending between the rim (240) and a portion of the body (201) Determining three-dimensional information of a single swirler (200) having:
Converting the three-dimensional information into a plurality of slices, each slice defining a cross-sectional layer of the unitary swirler (200);
Using a laser energy each saw including a step of forming successively a of the unitary swirler (200) by dissolving the metal powder,
Determining the three-dimensional information of the unitary swirler (200) is configured to direct air flow toward at least some of the plurality of vanes (208) and extends from a portion of the body (201). Determining a three-dimensional model of the unitary swirler (200) having an adapter (250) having a passageway (254) formed by an arcuate wall (256);
A method characterized by that . The method of claim 15 , wherein determining three-dimensional information of the single swirler (200) further comprises determining a three-dimensional model of the single swirler (200). Forming each layer of the unitary swirler (200) one after another by melting metal powder using laser energy further comprises dissolving a powder comprising at least one of cobalt chrome, HS188 and INCO625. The method of claim 15 . The step of sequentially forming each layer of the unitary swirler (200) by dissolving the metal powder using laser energy comprises dissolving the metal powder having a particle size between about 10 microns and about 75 microns. 16. The method of claim 15 , further comprising: The step of successively forming each layer of the unitary swirler (200) by dissolving the metal powder using laser energy comprises dissolving the metal powder having a particle size between about 15 microns and about 30 microns. The method of claim 18 further comprising: The step of determining the three-dimensional information of the single swirler (200) includes the step of determining a three-dimensional model of the single swirler (200) having a gap (216) positioned at least partially within the body (201). 16. The method of claim 15 , further comprising: The step of determining the three-dimensional information of the single swirler (200) determines a three-dimensional model of the single swirler (200) having at least one vane (209) having a different shape from another vane (208). 16. The method of claim 15 , further comprising: The method of claim 15 , wherein the adapter (250) has a groove (252) capable of receiving a brazing material. A body (201) having a unitary structure including a swirler hub (205) having a swirler shaft (11) ;
Are arranged circumferentially around said swirler shaft (11), and a plurality of vanes (208) extending from said hub (205),
An adapter (250) having a passage (254) configured to direct the flow of air toward at least some of the plurality of vanes (208) ;
The passage (254) is formed by an arched wall (256) extending from a portion of the body (201);
A single swirler (200), characterized by being manufactured using a rapid manufacturing process. 24. The unitary swirler (200) of claim 23 , wherein the rapid manufacturing process is a laser sintering process. 24. The unitary swirler (200) of claim 23 , wherein the rapid manufacturing process is DMLS. 24. The unitary swirler (200) of claim 23 , further comprising a rim (240) coaxial with the shaft (11). 27. The unitary swirler (200) of claim 26 , further comprising a wall (260) extending between a portion of the rim (240) and a portion of the hub (205). 24. The unitary swirler (200) of claim 23 , wherein each vane (208) has substantially the same shape. 24. A unitary swirler (200) according to claim 23 , wherein at least one vane (209) has a different shape than another vane (208). 24. A single swirler (200) according to claim 23 , wherein the body (201) has an insulating gap (216) located at least partially within the body (201).

Images